Gate-Shaped FRP Backrest Frame with Oblique Transverse Reinforcement

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Solution Overview

Problem

Existing frame structures for car seat backrests face challenges in achieving a balance between lightweight construction and high stiffness, particularly in FRP materials, where weight savings are limited and production costs are high due to complex shapes and inefficient material usage.

Innovation Solution

A frame structure featuring a gate-shaped profile with side frames and a transverse frame that connects obliquely, incorporating unidirectionally-oriented reinforcing fibers in a belt-shaped FRP sheet to enhance stiffness and load transmission, while reducing material usage and production complexity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If the frame structure is made of metal, then the stiffness is improved, but the weight increases and manufacturing complexity increases

Engineering Contradiction:
ImprovestiffnessVSAvoidweight
Core Design Contradiction:
StrengthVSWeight of moving object

Solution Approach 1:

The patent applies composite materials by combining resin with reinforcing fibers (such as glass fibers or carbon fibers) to create an FRP (fiber-reinforced plastic) frame structure. This composite material provides high stiffness comparable to metal while maintaining lightweight characteristics, directly resolving the contradiction between stiffness and weight.

Inventive Principle:
Principle #40Composite materials

Solution Approach 2:

The patent implements local quality by strategically positioning reinforcing fibers within the transverse frame, particularly concentrating them in areas requiring enhanced stiffness such as the center portion and regions connecting to side frames. This localized reinforcement achieves high stiffness where needed while minimizing overall material usage and weight.

Inventive Principle:
Principle #3Local quality

2Strength

If the plate thickness of the framework is increased to improve stiffness, then the stiffness is improved, but the weight savings are limited

Engineering Contradiction:
ImprovestiffnessVSAvoidweight savings
Core Design Contradiction:
StrengthVSWeight of moving object

Solution Approach 1:

Instead of increasing plate thickness, the patent uses composite materials with reinforcing fibers embedded in the resin framework. This approach achieves enhanced stiffness through material composition rather than geometric thickening, preserving weight savings while meeting stiffness requirements.

Inventive Principle:
Principle #40Composite materials

Solution Approach 2:

The patent applies reinforcing fibers locally in the transverse frame rather than uniformly throughout the entire structure. This selective reinforcement provides necessary stiffness in critical areas without adding unnecessary weight, effectively resolving the contradiction between stiffness improvement and weight savings.

Inventive Principle:
Principle #3Local quality

3Strength

If many ribs are provided to improve the left and right frame parts in stiffness, then the stiffness is improved, but the formability deteriorates and material usage increases

Engineering Contradiction:
ImprovestiffnessVSAvoidformability
Core Design Contradiction:
StrengthVSEase of manufacture

Solution Approach 1:

The patent uses composite materials with reinforcing fibers to achieve stiffness improvement without adding complex rib structures. The fibers provide structural reinforcement that enhances stiffness while maintaining the simplicity of the frame geometry, thereby preserving formability and reducing manufacturing complexity.

Inventive Principle:
Principle #40Composite materials

Solution Approach 2:

The patent extracts the stiffness-enhancing function from complex geometric features (ribs) and transfers it to the material composition (reinforcing fibers). This allows the frame to maintain its simple, easily formable geometry while achieving the required stiffness through material properties rather than structural complexity.

Inventive Principle:
Principle #2Taking out (Extraction)

4Strength

If a mandrel with three-dimensional braiding is used in RTM process, then the stiffness is improved, but the manufacturing process becomes burdensome and costly

Engineering Contradiction:
ImprovestiffnessVSAvoidmanufacturing process complexity
Core Design Contradiction:
StrengthVSEase of manufacture

Solution Approach 1:

The patent employs composite materials with reinforcing fibers that can be directly embedded in the resin during standard molding processes. This approach achieves high stiffness without requiring complex pre-formed mandrels or three-dimensional braiding, simplifying the manufacturing process while maintaining structural performance.

Inventive Principle:
Principle #40Composite materials

Solution Approach 2:

The patent changes the manufacturing approach by using reinforcing fibers that can be processed through conventional molding techniques rather than requiring specialized RTM processes with complex mandrels. This parameter change in manufacturing methodology reduces process complexity and cost while achieving the desired stiffness through optimized fiber placement and resin composition.

Inventive Principle:
Principle #35Parameter changes

Data Source

PatentUS9132760B2Frame structure for backrest and method for manufacturing the same
Publication Date: 2015.09.15 TORAY INDUSTRIES INC
  • US9132760B2 patent drawing
  • US9132760B2 patent drawing
  • US9132760B2 patent drawing

AI summary

A frame structure for a backrest made of a resin and having a gate-shaped profile includes side frames extending parallel to each other on both sides thereof and a transverse frame extending like a sheet between top portions of the side frames integrally connected to the transverse frame, wherein the transverse frame connects to backrest back-side portions of the side frames at the top portions and connects to backrest front-side portions of the side frames at bottom portions, the transverse frame being formed into a sheet-like shape smoothly extending obliquely with respect to the side frames in a longitudinal cross section, and provided with reinforcing fibers extending continuously or intermittently at least between both side frames.